Gema FPS16 Guide

En
Translation of the original operating instructions
Operating instructions and spare parts list
Fresh powder system
FPS16

V 07/21
Documentation FPS16 Fresh powder system
© Copyright 2005 Gema Switzerland GmbH
All rights reserved.
This publication is protected by copyright. Unauthorized copying is prohib-
ited by law. No part of this publication may be reproduced, photocopied,
translated, stored on a retrieval system or transmitted in any form or by
any means for any purpose, neither as a whole nor partially, without the
express written consent of Gema Switzerland GmbH.
MagicCompact, MagicCylinder, MagicPlus, MagicControl, OptiFlex, Opti-
Control, OptiGun, OptiSelect, OptiStar and SuperCorona are registered
trademarks of Gema Switzerland GmbH.
OptiFlow, OptiCenter, OptiMove, OptiSpeeder, OptiFeed, OptiSpray, Op-
tiSieve, OptiAir, OptiPlus, OptiMaster, MultiTronic, EquiFlow, Precise
Charge Control (PCC), Smart Inline Technology (SIT) and Digital Valve
Control (DVC) are trademarks of Gema Switzerland GmbH.
All other product names are trademarks or registered trademarks of their
respective holders.
Reference is made in this manual to different trademarks or registered
trademarks. Such references do not mean that the manufacturers con-
cerned approve of or are bound in any form by this manual. We have en-
deavored to retain the preferred spelling of the trademarks, and registered
trademarks of the copyright holders.
To the best of our knowledge and belief, the information contained in this
publication was correct and valid on the date of publication. Gema Swit-
zerland GmbH makes no representations or warranties with respect to the
contents or use of this publication, and reserves the right to revise this
publication and make changes to its content without prior notice.
For the latest information about Gema products, visit
www.gemapowdercoating.com.
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www.gemapowdercoating.com/patents or
www.gemapowdercoating.us/patents.
Printed in Switzerland
Gema Switzerland GmbH
Mövenstrasse 17
9015 St.Gallen
Switzerland
Phone: [phone]
Fax: [phone]
Email: [email protected]

V 07/21
FPS16 Table of contents •1
Table of contents
General safety regulations 3
Safety symbols (pictograms)...................................................................................3
Intended use ...........................................................................................................3
Product-specific safety measures...........................................................................4
FPS16 Fresh powder system.....................................................................4
About this manual 5
General information ................................................................................................5
Function description 7
Field of application..................................................................................................7
Overview.................................................................................................................7
Versions.....................................................................................................7
Technical Data 9
FPS16 Fresh powder system..................................................................................9
Conveying performance.............................................................................9
Electrical data ............................................................................................9
Pneumatic data........................................................................................10
Dimensions ..............................................................................................10
Container specifications (big bag) ...........................................................10
Equipment description 11
Structure................................................................................................................11
Support.....................................................................................................12
Lifting device for large containers............................................................12
Fluidizing/suction tube .............................................................................12
Lifting device for fluidizing/suction tube...................................................12
Vibrating plate..........................................................................................12
Control......................................................................................................12
Powder pump...........................................................................................12
Function ................................................................................................................13
Powder flow detection..............................................................................13
Operating and display elements...........................................................................14
Control cabinet.........................................................................................14
Control module.........................................................................................15
Start-up 17
Electrical allocation...............................................................................................17
Main module inputs..................................................................................17
Main module outputs................................................................................17
Additional module inputs..........................................................................18
Additional module outputs........................................................................18
Pneumatic connection...........................................................................................18
Powder connections..............................................................................................18

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2•Table of contents FPS16
Start-up................................................................................................................. 19
Parameterization .................................................................................................. 19
The standard display looks as follows:.................................................... 19
Parameter input display:.......................................................................... 19
Entering and selecting a menu option..................................................... 20
Powder flow detection .......................................................................................... 22
Overview.................................................................................................. 22
Procedure description.............................................................................. 23
Adjusting the threshold values ................................................................ 23
Container change / color change / cleaning 25
Container change................................................................................................. 25
Color change ........................................................................................................ 25
Cleaning................................................................................................................ 26
Maintenance 27
General information.............................................................................................. 27
Troubleshooting 29
General information.............................................................................................. 29
Spare parts list 31
Ordering spare parts............................................................................................. 31
FPS16 Fresh powder system –spare parts list.................................................... 32
FPS16 Fresh powder system –spare parts......................................................... 33
Fluidizing/suction tube.......................................................................................... 34
Fluidizing/suction tube.......................................................................................... 35
Control.................................................................................................................. 36
Control.................................................................................................................. 37
Pinch valve ........................................................................................................... 38

V 07/21
FPS16 General safety regulations •3
General safety regulations
This chapter sets out the fundamental safety regulations that must be fol-
lowed by the user and third parties using the FPS16 Fresh powder sys-
tem.
These safety regulations must be read and understood before the Fresh
powder system is put into operation.
Safety symbols (pictograms)
The following warnings with their meanings can be found in the Gema
Switzerland operating instructions. The general safety precautions must
also be followed as well as the regulations in the operating instructions.
DANGER!
danger due to live electricity or moving parts Possible consequences:
Death or serious injury
ATTENTION!
Improper use of the equipment could damage the machine or cause it to
malfunction. Possible consequences: minor injuries or damage to equip-
ment
NOTE:
Useful tips and other information
Intended use
–The Fresh powder system is state of the art equipment that con-
forms to the recognized technical safety regulations and is designed
for normal powder coating applications.
–Any other use is not considered as intended use. The manufacturer
shall not be liable for damage resulting from such use; the user
bears sole responsibility for such actions. If the Fresh powder sys-
tem is to be used for other purposes or other substances outside of
our guidelines, then Gema Switzerland GmbH should be consulted.
–Observance of the operating, service and maintenance instructions
specified by the manufacturer is also part of the intended use. The
Fresh powder system should only be used, maintained and started
up by trained personnel informed and familiar with the possible haz-
ards involved.

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4•General safety regulations FPS16
–Start-up (i.e. operation of its intended use) is not allowed until it has
been established that the Fresh powder system has been installed
and wired according to the EU Machinery Directive (2006/42/EC).
EN 60204-1 (machine safety) must also be observed.
–Unauthorized modifications to the Fresh powder system exempt the
manufacturer from any liability from resulting damage.
–The relevant accident prevention regulations, as well as other gen-
erally recognized safety regulations, occupational health and struc-
tural regulations are to be observed.
–Furthermore, the country-specific safety regulations also must be
observed.
Explosion protection
Protection type
II 3D
IP54
Product-specific safety measures
–Installation work performed by the customer must be carried out ac-
cording to local regulations.
–All components must be grounded according to the local regulations
before start-up.
–Due to accident risk and depending on the placement of the fresh
powder system, the safety barriers have to be placed in accordance
to the local regulations!
–The big bag equipped with antistatic loops is grounded via the FPS
hang-up plate.
–Grounding resistance should be checked regularly and should not
exceed 108ohm.
–If the big bag is detached from the hang-up plate, ensure that it is
appropriately grounded, as friction charging may occur during trans-
ferring processes.
FPS16 Fresh powder system
The Fresh powder system is part of the plant and therefore integrated in
the safety concept of the plant.
If it is to be used in a manner outside the scope of the safety concept,
then corresponding measures must be taken.
NOTE:
For further information, see the more detailed Gema safety regula-
tions!

V 07/21
FPS16 About this manual •5
About this manual
General information
This operating manual contains all important information which you re-
quire for the working with the Fresh powder system. It will safely guide
you through the start-up process and give you references and tips for the
optimal use of your new powder coating system.
Information about the function mode of the individual system components
–booth, gun control unit, manual gun or powder injector –should be ref-
erenced to their corresponding documents.
DANGER:
Working without operating instructions
Working without operating instructions or with individual pages
from the operating instructions may result in damage to property
and personal injury if relevant safety information is not observed.
►Before working with the device, organize the required documents and
read the section on "Safety regulations".
►Work should only be carried out in accordance with the instructions in
the relevant documents.
►Always work with the complete original document.

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FPS16 Function description •7
Function description
Field of application
The FPS16 Fresh powder system is built exclusively for electrostatic coat-
ing with organic powders. Any other use is not considered as intended
use. The manufacturer is not responsible for any incorrect use and the
risks associated with such actions are assumed by the user alone.
Overview
The Fresh powder system is suited for supplying the powder coating
equipment with powder from large containers (Big Bag). The powder sup-
ply takes place continuously from the large container and in accordance
to the consumption in the coating plant. The powder transport is automat-
ically switched on and off by messages from the level sensor in the pow-
der container. The powder is aspirated in pulses by a vacuum, and sub-
sequently transported with conveying air.
Versions
The FPS16 Fresh powder system is available either with one or with two
powder pumps (FPS16-2). The FPS16-2 version permits a powder
transport from the large powder container to two different destinations.
FPS16-1 FPS16-2

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FPS16 Technical Data •9
Technical Data
FPS16 Fresh powder system
Conveying performance
FPS16
Conveying performance
3500-5000 g/min for each pump*
(according to the material to be
conveyed, suction and conveying
length, powder preparation etc.)
Conveying line
up to 8 m (5 kg/min conveying per-
formance)
8-16 m (4 kg/min conveying per-
formance)
16-25 m (3.5 kg/min conveying per-
formance)
Hose diameter Transport side
NW 16 mm
Suction line
up to 5 m
Material to be conveyed
Coating powder
Remaining quantity
< 5% of the original container con-
tent*
*The indicated values are guide values; possible deviations are depend-
ent on the powder type and the large container (BigBag) geometry!
Electrical data
FPS16
Power supply
3x400 VAC
24 VDC
Frequency
50/60 Hz

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10 •Technical Data FPS16
Pneumatic data
FPS16
Compressed air
5-8 bar / 101-145 psi
Air consumption
max. 0.5 Nm³/h for lifting procedure
max. 12 Nm³/h for each PP0x
Powder pump
max. 0.5 Nm³/h for fluidization
Max. water vapor content
1.3 g/m³
Max. oil vapor content
0.1 mg/m³
Dimensions
FPS16
Weight
approx. 340 kg
Max. load
500 kg
Container base area
max. 800 x 1000 mm
Container height incl. loops
1160/1260/1360 mm
Container specifications (big bag)
FPS16
Suspension system
4-point loops
Version
square, no partition walls, with
emptying funnel
Safety factor
min. 5:1 for disposable use
min. 8:1 for reuse
Material incl. suspension loops
conductive, R<108ohm

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FPS16 Equipment description •11
Equipment description
Structure
The FPS16 Fresh powder system consists of:
Fig.
1
: Structure
1 Fluidizing/suction tube
2 Control
3 Powder pump
4 Support
5 Vibrating plate
6 Lifting device for container
7 Lifting device for fluidiz-
ing/suction tube
7
1
3
6
5
2
4

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12 •Equipment description FPS16
Support
The fresh powder system support is formed by three wall elements and
the crossbeam for the lifting devices. The wall elements must be installed
on the floor, so that the stability under load can be ensured. The cross-
beam can be installed, depending on the container, on three different
heights.
Lifting device for large containers
The lifting device for large containers consists of the hang up plate and
two pneumatic cylinders. The operation and the control takes place by the
attached control cabinet.
Fluidizing/suction tube
The fluidizing/suction tube enables the loosening of the powder in the
container, and aspirates the powder for the powder pump.
Lifting device for fluidizing/suction tube
The fluidizing/suction tube can be lifted manually by a cable and can be
fixed in this position by hooking-in the final loop. The fluidizing/suction
tube is lifted only during the change of the large container.
Vibrating plate
When using the vibrating plate, the constant powder transport is guaran-
teed. The vibrating plate is hung on the hang-up plate by means of two
spring hooks and is then laid loosely onto the Big Bag. The vibrating op-
eration is started automatically every time the suction is switched on.
However, the vibration can be manually switched on and off using an ad-
ditional switch, and a light indicates the condition.
Control
All operation and control elements for the Fresh powder system are im-
plemented in the laterally attached control unit.
Powder pump
The laterally attached powder pump aspirates the powder, if required, by
the fluidizing/suction tube and ensures the transport to the powder con-
tainer in the coating plant. Please observe the operating manual of the
corresponding powder pump!

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FPS16 Equipment description •13
Function
In the starting position of the Fresh powder system, the fluidizing/suction
tube is lifted up and the lifting cylinders for the large container are low-
ered.
The large powder container is now put into the support by a pallet lifting
truck. All four lifting loops are hung up to the bolts; an unintentional hang-
out will be prevented by the existing rubber straps. The large powder con-
tainer is opened now, and the fluidizing/suction tube is slowly lowered into
the powder. Now press the Conveying ready key on the control unit and
the powder transport will be switched on, according to requirement. The
lifting procedure of the container is now also automatically switched on by
reaching the max. lifting weight (adjustable depending on cylinder pres-
sure).
Powder flow detection
The powder transport is monitored by the powder flow detection during
the conveying procedure. If during a powder requirement by the level
sensor no or too little powder flows through the conveying line within a de-
fined time, this will be recognized by the installed sensor. This powder
shortage actuates an up/down procedure of the powder container (Big
Bag). This procedure is automatically interrupted when the Powder
shortage signal is reset, and otherwise constantly repeated during an ad-
justable time. If the powder shortage will not be reset by the up/down pro-
cedure during a defined time, an alarm message for the operating per-
sonnel will be released.

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14 •Equipment description FPS16
Operating and display elements
Control cabinet
The control cabinet contains the following operating elements:
Fig.
2
: Control cabinet view
Pos.
Function
Description
1
Main switch
The complete control unit is disconnected from the mains with the
main switch
2
Conveying ready
The powder transport readiness takes place by pressing the Con-
veying ready key
The readiness is indicated by the indicator lamp (pos. 6)
Therewith, the lifting up of the large container will be started. De-
pending on the weight in the large container, the lifting up takes
place after the powder discharge, if the weight of the container is
smaller than the adjusted lifting power of the pneumatic cylinders
As soon as the level sensor of the powder container detects “emp-
ty”, the powder transport and the vibrating plate switch on automati-
cally
3
Cleaning
By pressing the Cleaning key, the rinsing procedure of the powder
pump will be started. The suction unit must be lifted manually and
can be blown off with compressed air and can be cleaned (Attention
–large dust formation possible!)
4
Conveying off
By pressing the Conveying off key, the powder conveying proce-
dure will be interrupted and the large powder container lowers im-
mediately.
5
Big Bag empty
This red indicator lamp illuminates, if the powder flow sensor does
not detect powder during a defined time. Now the large powder con-
tainer must be checked by the operating personnel and probably be
changed
5
1
2, 3, 4
6

V 07/21
FPS16 Equipment description •15
Control module
Fig.
3
: Control module
1 Power pack
2 Main module
3 Additional module
2
3
1

V 07/21
FPS16 Start-up •17
Start-up
Electrical allocation
ATTENTION:
The equipment and the vibrating plate are necessarily to be ground-
ed with the ground connection!
►As ground conductor, use a copper cable with a cross-section of at
least 4 mm²!
Main module inputs
Entry
Description
I1
External interlocking/Automatic operating mode must
be operated with switch –control unit is ready for op-
eration. Powder box will be lifted
I2
External fresh powder requirement (pump 1)
I3
External fresh powder requirement (pump 2)
I4
Activate cleaning mode
I5
Reserve
I6
Reserve
I7
Analog input 0-10 V / pressure sensor for pump 1
I8
Analog input 0-10 V / pressure sensor for pump 2
Main module outputs
Output
Description
Q1
main solenoid valves
Q2
Solenoid valve –lift cylinder
Q3
Warning lamp - no powder
Q4
Potential-free contact –no powder (max. voltage 230
VAC)

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18 •Start-up FPS16
Additional module inputs
Entry
Description
I1-I4
Reserve
Additional module outputs
Output
Description
Q1
Conveying on - pump 1
Q2
Conveying on - pump 2
Q3
Pinch valve –preventing excess air suction of pump 1
Q4
Pinch valve –preventing excess air suction of pump 2
Pneumatic connection
The compressed air must be connected to the control unit input in ac-
cordance to the specifications. All compressed air consumers will be sup-
plied by the control unit.
Description
1
Lift/lower
2
Fluidizing air
P min = 0.5 bar
3
Compressed air supply, pinch valves (FPS16-2 version only)
P max. = 3.0 bar
Powder connections
The powder hose must be connected according to the corresponding
powder pump(s).
1
2
3